Bathtub overflow and drain assembly

ABSTRACT

A bathtub waste and overflow drain assembly for use with a thermoformed bathtub including a sidewall and a base. An overflow housing interfaces with an overflow protrusion extending outwardly from the sidewall of the bathtub. Waste drain housing interfaces with a waste drain protrusion extending downwardly from the base of the bathtub. A flexible tube assembly fluidly couples the overflow housing and the waste drain housing.

BACKGROUND AND SUMMARY OF THE DISCLOSURE

The present invention relates generally to a fluid transport assembly and, more particularly, to an overflow and drain assembly for a bathtub.

Conventional bathtub and overflow assemblies may present installation difficulties given the connections required between the overflow drain in the bathtub sidewall and the waste drain in the bathtub base. Additionally, thin walled thermoformed bathtubs traditionally require an overflow cover on the inside of the tub, often presenting an aesthetically unpleasant appearance.

The present disclosure provides a bathtub overflow and drain assembly, and related method of manufacture, wherein a thermal forming tool may draw an overflow pocket within the surface of the bathtub sidewall. This overflow pocket may be trimmed to define an outwardly extending protrusion or extension received within an overflow housing. A flange of the overflow housing may be secured in place with a conventional fastener, such as an adhesive gasket.

Similarly, a thermal forming tool may draw a drain pocket within the surface of the bathtub base. This drain pocket may be trimmed to define a downwardly extending protrusion or extension may be formed within the base of the bathtub and is received within an integrated overflow waste drain housing. Installation of the bathtub is facilitated since both the overflow and the drain are incorporated in the bathtub design, wherein the installer only has to align the waste drain housing with the waste pipe on the floor. A flexible hose assembly illustratively couples the overflow housing with the waste drain housing.

According to an illustrative embodiment of the present disclosure, a fluid transport assembly is provided for a bathtub including a sidewall and a base. The fluid transport assembly includes an overflow housing interfacing with an overflow protrusion extending outwardly from a sidewall of a bathtub. A waste drain is configured to be fluidly coupled to a base of the bathtub. A tube assembly fluidly couples the overflow housing and the waste drain.

According to another illustrative embodiment of the present disclosure, a fluid transport assembly is provided for a bathtub including a sidewall and a base. The fluid transport assembly includes an overflow, and a waste drain housing interfacing with a waste drain protrusion extending downwardly from a base of a bathtub. A tube assembly fluidly couples the overflow and the integrated drain housing. A waste shoe interfaces with an opening in the waste drain housing.

According to another illustrative embodiment of the present disclosure, a fluid transport assembly is provided for a bathtub including a sidewall and a base. The fluid transport assembly includes an overflow housing that interfaces with an overflow protrusion extending outwardly from the sidewall of a bathtub. An integrated drain housing interfaces with a waste drain protrusion extending downwardly from the base of the bathtub. A flexible tube assembly fluidly couples the overflow housing and the waste drain housing.

Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to the accompanying figures in which:

FIG. 1 is a top perspective view of a bathtub including an overflow and drain assembly of the present disclosure;

FIG. 2 is a bottom perspective view of the bathtub including overflow and drain assembly of FIG. 1;

FIG. 3 is a partially exploded perspective view of the overflow and drain assembly of FIG. 1;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 2;

FIG. 5 is a rear exploded perspective view of the overflow and drain assembly of FIG. 1;

FIG. 6 is a front exploded perspective view of the overflow and drain assembly of FIG. 1; and

FIG. 7 is a flow chart of an illustrative method of manufacturing the overflow and drain assembly of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

Referring initially to FIGS. 1 and 2, a thermoformed bathtub 10 is shown as including a sidewall 12 extending upwardly from a base or bottom wall 14. A bathtub waste and overflow drain assembly 20 is fluidly coupled to the bathtub 10 and includes a waste drain 22 and an overflow 24.

With reference to FIG. 3, the sidewall 12 and the base 14 of the bathtub 10 are illustratively thermoformed from an acrylic material. During the thermoforming process, an overflow protrusion or extension 26 is formed to extend outwardly from the sidewall 12 and defines an opening 27. Similarly, a waste drain protrusion or extension 28 is formed to extend downwardly from the base 14 and defines an opening 29. The overflow protrusion 26 and the drain protrusion 28 are fluidly coupled to the overflow 24 and the waste drain 22, respectively, of the bathtub waste and overflow drain assembly 20.

The bathtub waste and overflow drain assembly 20 illustratively includes an overflow housing 30 that interfaces with the overflow protrusion 26 extending outwardly from the sidewall 12 of the bathtub 10. A waste drain housing 32 is configured to be fluidly coupled to the drain protrusion 28 extending downwardly from the base 14 of the bathtub 10. A tube assembly 40 fluidly couples the overflow housing 30 and the waste drain housing 32.

The overflow housing 30 illustratively includes a body 42 including a tub interface portion 44 and an outlet tube 46. The body 42 may be formed of a polymer, such as polyvinylchloride (PVC), polypropylene (PP) or acrylic. The tub interface portion 44 defines a first fluid passageway 48 and the outlet tube 46 defines a second fluid passageway 50. The first fluid passageway 48 is illustratively positioned perpendicular to the second fluid passageway 50. Illustratively, the first fluid passageway 48 may slope away from the tub sidewall 12 to prevent water pooling.

With reference to FIGS. 5 and 6, the tub interface portion 44 includes a face 52 defining an opening 54 that interfaces with the opening 27 of the overflow protrusion 26. The opening 54 in the face 52 is elongated and at least partially rounded. Moreover, the face 52 illustratively conforms to the outer surface 56 of the sidewall 12. The overflow protrusion 26 is illustratively received within the opening 54 of the tub interface portion 44. The tub interface portion 44 further comprises a downwardly extending stabilizing extension 58 configured to contact the sidewall 12 of the bathtub 10. The stabilizing extension 58 illustratively includes a plurality of openings 60 which may reduce required material and receive an adhesive.

In one illustrative embodiment, an adhesive gasket 62 is used to secure the overflow housing 30 to the bathtub 10. More particularly, the adhesive gasket 62 may secure the face 52 to the sidewall 12 of the bathtub 10. Other conventional securing means, such as an adhesive, may be used to secure the overflow housing 30 to the bathtub 10.

The waste drain 22 illustratively includes a conventional toe-tap or pop-up waste drain 64 positioned within an upwardly facing cavity 66 defined by the waste drain protrusion 28 from above the base 14 of the bathtub 10. The toe-tap waste drain 64 illustratively includes a spring-biased plug 68 that may toggle between raised and lowered positions by being pressed downwardly by a user. An illustrative pop-up drain is shown in U.S. Pat. No. 4,103,372 to Cuschera, the disclosure of which is expressly incorporated herein by reference.

With further reference to FIGS. 3, 5 and 6, the waste drain 22 includes the integrated drain housing 32 that interfaces with the waste drain protrusion 28 extending downwardly from the base 14 of the bathtub 10. The integrated drain housing 32 includes a T-shaped body 70 including a passageway or chamber 72 with at least three openings 74, 76, 78. First opening 74 is defined by a cylindrical wall 75 and is fluidly coupled to the opening 29 of the waste drain protrusion 28. Second opening 76 is defined by a cylindrical tube 77 and is fluidly coupled to the tube assembly 40. Third opening 78 is defined by cylindrical wall 79 and is fluidly coupled to a waste shoe 80. The first opening 74 is illustratively round to concentrically receive the waste drain protrusion 28 and is in fluid communication with the opening 29.

A stabilizing support 82 of the drain housing 32 extends from the body 70 outwardly from the first opening 74. The stabilizing support 82 is configured to assist in stabilizing the body 70 and includes a plurality of grooves 84. An adhesive may secure the drain housing 32 to the base 14 of the bathtub 10. Illustratively, the adhesive may be received within the grooves 84 of the stabilizing support 82. The integrated drain housing 32 may also interface with the base 14 of the bathtub 10 through an adhesive gasket (not shown).

The tube assembly 40 illustratively includes a flexible tube 86 having a proximal or upper end 88 and a distal or lower end 90, wherein the proximal end 88 interfaces with the overflow housing 30, and the distal end 90 interfaces with the drain housing 32 through an elbow connector 92. The flexible tube 86 is illustratively formed of a resilient material, such as polyvinylchloride (PVC) or silicone. A hose clamp 94 illustratively secures the upper end 88 of the flexible tube 86 to the overflow housing 30. The distal end 90 of the tube 86 gradually increases in diameter wherein a slip joint nut 96 and a hose clamp 97 illustratively secure the distal end 90 of the tube 86 to a first or proximal end 98 of the elbow connector 92. The second opening 76 of the drain housing 32 secures to the second or distal end 100 of the elbow connector 92. Conventional securing means, such as mating threads or adhesives, may be used to secure the cylindrical tube 77 of the drain housing 32 to the distal end 100 of the elbow connector 92.

The waste shoe 80 may be secured to the third opening 78 of the drain housing 32 through an adhesive gasket 102. The waste shoe 80 illustratively includes a body 104 having an outlet 106 fluidly coupled to a conventional drain pipe 108 (FIG. 4). The waste shoe 80 may be formed of a polymer, such as polypropylene (PP).

An illustrative method 200 is shown in FIG. 7, where the bathtub waste and overflow drain assembly 20 is manufactured during the thermoforming process of the bathtub 10 where the sidewall 12 and the base 14 are formed. At step 202, a first thermal forming tool is used during the thermoforming process to draw an overflow pocket in the sidewall 12 of the bathtub 10. At step 204, this overflow pocket is illustratively trimmed by a cutting device to define the outwardly extending overflow protrusion 26.

The method continues at step 206 by using a thermal forming tool during the thermoforming process to draw a drain pocket within the base 14 of the bathtub 10. At step 208, this drain pocket is then trimmed by a cutting device to define downwardly extending drain protrusion 28 within the base 14 of the bathtub 10.

At step 210, the overflow housing 30 is fluidly coupled to the waste drain housing 32 through the tube assembly 40 including flexible tube 86 and elbow connector 92. At step 212, the overflow protrusion 26 is received within the opening 54 of the overflow housing 30. At step 214, the face 52 of the overflow housing 30 is illustratively secured to the sidewall 12 of the bathtub 10 with adhesive gasket 62. At step 216, the drain protrusion 28 is received within the opening 74 of the drain housing 32. At step 218, the drain housing 32 is illustratively secured to the base 14 of the bathtub 10 with an adhesive. The toe-tap waste drain 64 is then positioned within the cavity 66 defined by the drain protrusion 28 at step 220.

With the bathtub waste and overflow drain assembly 20 of the present disclosure, installation of the bathtub 10 is facilitated since both the overflow 24 and the waste drain 22 are incorporated in the bathtub design. During installation, the installer simply aligns the waste drain housing 32 and the waste shoe 80 with the drain pipe 108 in the floor. The flexible tube assembly 40 illustratively couples the overflow housing 30 with the waste drain housing 32.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims. 

1. A fluid transport assembly for a bathtub including a sidewall and a base, the fluid transport assembly comprising: an overflow housing configured to interface with an overflow protrusion extending outwardly from a sidewall of a bathtub; a waste drain configured to be fluidly coupled to a base of the bathtub; and a tube assembly fluidly coupling the overflow housing and the waste drain.
 2. The fluid transport assembly of claim 1, wherein the overflow protrusion is thermoformed with the bathtub.
 3. The fluid transport assembly of claim 1, wherein the tube assembly is flexible.
 4. The fluid transport assembly of claim 1, wherein the overflow housing comprises: a tub interface portion including a face with an opening configured to interface with the overflow protrusion; and an outlet tube fluidly coupled with the opening in the face and creating a fluid passageway that contains at least one bend.
 5. The fluid transport assembly of claim 4, wherein the opening in the face is elongated and at least partially rounded.
 6. The fluid transport assembly of claim 4, wherein the face of the tub interface portion is configured to conform to an outer surface of the sidewall.
 7. The fluid transport assembly of claim 4, wherein the tub interface portion further comprises a stabilizing extension.
 8. The fluid transport assembly of claim 7, wherein the stabilizing extension contains at least one opening.
 9. The fluid transport assembly of claim 1, further comprising an adhesive gasket for securing the face of the overflow housing to the sidewall of the bathtub.
 10. The fluid transport assembly of claim 1, wherein the waste drain includes a waste drain housing configured to interface with a waste drain protrusion extending downwardly from the base of the bathtub.
 11. A fluid transport assembly for a bathtub including a sidewall and a base, the fluid transport assembly comprising: an overflow; a waste drain housing configured to interface with a waste drain protrusion extending downwardly from a base of a bathtub; a tube assembly coupling the overflow and the waste drain housing; and a waste shoe interfacing with an opening in the waste drain housing.
 12. The fluid transport assembly of claim 11, wherein the waste drain protrusion is thermoformed with the bathtub.
 13. The fluid transport assembly of claim 11, wherein the waste drain housing comprises: a T-shaped body including at least three openings, including a first opening fluidly coupled to the waste drain protrusion; a second opening fluidly coupled to the tube assembly; a third opening fluidly coupled to the waste shoe; and a support for the base extending from the first opening.
 14. The fluid transport assembly of claim 13, wherein the first opening of the waste drain body concentrically receives the waste drain protrusion.
 15. The fluid transport assembly of claim 13, wherein the support contains ridges.
 16. The fluid transport assembly of claim 11, wherein the overflow includes an overflow housing that interfaces with an overflow protrusion extending outwardly from a sidewall of the bathtub.
 17. A fluid transport assembly for a bathtub including a sidewall and a base, the fluid transport assembly comprising: an overflow housing configured to interface with an overflow protrusion extending outwardly from a sidewall of a bathtub; a waste drain housing configured to interface with a waste drain protrusion extending downwardly from a base of the bathtub; and a flexible tube assembly fluidly coupling the overflow housing and the waste drain housing.
 18. The fluid transport assembly of claim 17, wherein the flexible tube assembly comprises: a flexible tube having a proximal end and a distal end, wherein the proximal end is interfaced with the overflow housing and the distal end gradually increases in diameter; and an elbow connector interfaces the flexible tube and the waste drain housing.
 19. The fluid transport assembly of claim 18, wherein the elbow connector clamps within the distal end of the flexible tube.
 20. The fluid transport assembly of claim 17, wherein the flexible tube assembly further comprises a hose clamp for connecting the flexible tube to the overflow housing.
 21. The fluid transport assembly of claim 17, wherein the overflow housing and the waste drain housing are interfaced with the bathtub using at least one gasket, wherein the at least one gasket includes adhesive. 